Method of manufacturing velvet plush and article thereof

ABSTRACT

A method of manufacturing a velvet plush article includes the steps of: weaving a greige cloth by interweaving face yarns and backing yarns, wherein the face yarns are selected from single-ply bright trilobal yarns and two-ply yarns and the backing yarns are selected from FDY or DTY yarn; pre-processing the greige cloth by brushing, first setting, singeing and second setting the greige cloth sequentially; dyeing and/or printing the greige cloth; and finishing the greige cloth by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting the greige cloth. Accordingly, a velvet plush article having superior smoothness and softness for providing a superior touch and feel comfort is achieved. The velvet plush article may be a velvet plush throw or blanket, or a velvet plush cloth for further processing.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to velvet plush, and more particularly to a method of manufacturing velvet plush throw which utilizes synthetic fiber to produce a particularly soft and smooth velvet plush throw.

2. Description of Related Arts

Velvet plush has a generally soft and smooth texture and is a very popular materials used in textiles. Recently, velvet plush throw, blanket or the like is very popular in regular household use because its softness and smoothness provides a very great feel and touch sensation to a user. However, in order to manufacture a velvet plush throw, blanket or the like with superior feel and touch sensation, the cost of manufacture is very high. On the contrary, in order to manufacture a velvet plush throw and blanket with reasonable manufacture cost, the quality of the velvet plush throw is low. There is no way to manufacture a high quality velvet plush throw with a cost-effective method.

For example, silk is the traditional material which provides superior softness and smoothness. However, silk is also a very expensive raw material and therefore it is not an option when manufacturing cost is a concern.

On the other hand, synthetic materials such as polyester and nylon are more reasonable in price. However, the quality of a velvet plush cloth made in polyester or nylon is relatively low.

Conventional method for manufacturing a tufted surface involves needling and adding the tufted pile onto a backing, which is also incapable of providing a smooth and soft tufted surface of high quality with evenly distributed pile layer.

SUMMARY OF THE PRESENT INVENTION

The invention is advantageous in that it provides a method of manufacturing velvet plush which can utilize synthetic materials to produce a high quality velvet plush article.

Another advantage of the invention is to provide a method of manufacturing velvet plush which can utilize synthetic materials to produce a velvet plush article having superior smoothness and softness so as to provide a superior touch and feel comfort.

Another advantage of the invention is to provide a method of manufacturing velvet plush which can utilize synthetic materials to produce a velvet plush article through an automated process with lowered cost and higher quality.

Another advantage of the invention is to provide a velvet plush article through a method of manufacture thereof so as to provide a velvet plush article having superior smoothness and softness while providing flexibilities in dyeing and printing.

Another advantage of the invention is to provide a velvet plush article through a method of manufacture thereof so as to provide a velvet plush article having superior smoothness and softness so as to provide a superior touch and feel comfort.

Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.

According to the present invention, the foregoing and other objects and advantages are attained by a method of manufacturing a velvet plush article, comprising the steps of:

(a.1) weaving a greige cloth by interweaving face yarns and backing yarns, wherein the face yarns are selected from a group consisting of single-ply bright trilobal yarns with 75D/144F, 90D/144F, 100D/144F or 150D/288F and two-ply yarns with 120D/288F-300D/574F, wherein the backing yarns are selected from FDY 68D-100D or DTY 100D-150D;

(b.1) pre-processing the greige cloth obtained from step (a) by brushing, first setting, singeing and second setting the greige cloth sequentially;

(c.1) dyeing the greige cloth after step (b.1) to form a colored greige cloth; and

(e.1) finishing the colored greige cloth by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting the colored greige cloth.

Alternately, after the step (b.1) or (c.1), the method of manufacturing a velvet plush article further comprises the steps of:

(d.1) printing the greige cloth obtained from the step (b.1) or printing the colored greige cloth obtained from the step (c.1) to form a printed greige cloth; and

(e.1) finishing the colored greige cloth or the printed greige cloth by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting the colored or printed greige cloth sequentially.

Preferably, in step (a.1), a first and a second filaments are provided and a ratio of the first filament to the second filament is 4:1, wherein the first filament is a backing filament.

Preferably and in particular, in step (b.1), the brushing involves brushing along a frontward direction as well as brushing at a backward direction; the first setting involves heat-setting at 130-120° C. at a rolling speed of 25 m/min; the singeing involves a sequential rolling for six times at a frontward, backward, backward, frontward, backward and backward directions; the second setting involves heat-setting at 170-180° C. at a rolling speed of 25 m/min.

In particular, in the step (c.1), dyeing the greige cloth includes bathing in dye fluid and rinsing by water. Preferably, an additional dyeing time is required for bathing and a pH of the water for rinsing is neutral or has a lowest acidity for providing a smooth and bright surface. The additional dyeing time for bathing is 20 minutes.

In particular, in the step (d.1), printing includes the steps of brushing at a frontward direction, setting at 150° C. at a rolling speed of 25 m/min, and printing a preset pattern.

Preferably, in the step (e.1), softening includes washing to add acidity until the greige cloth is soft and then neutralizing the greige cloth until a pH of the greige cloth is neutral. It is worth mentioning if the pH is smaller than 7, then hair loss will occur. If the pH is greater than 7, the greige cloth will be hardened; drying includes drying under 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300rpm and a lower drying channel operated at 1200 rpm; brushing includes brushing for two times; stentering includes stentering at a frontward direction and a backward direction;

heat-setting includes heat-setting under 150° C. at a rolling speed of 25 m/min with soft air; singeing includes singeing at a frontward direction and a backward direction, and preferably includes singeing at a backward, backward, frontward, frontward, backward, frontward, backward and frontward directions sequentially; shearing includes shearing at a frontward, backward, backward, frontward, frontward, frontward, backward and backward directions sequentially such that the final direction of the hair at a frontward direction and at a backward direction are the same; and final heat-setting includes heat-setting at 190° C. at a rolling speed of 30 m/min.

In accordance with another aspect of the invention, the present invention comprises a velvet plush article, comprising:

a flat body having a middle layer defining a top surface and a bottom surface, and at least one pile layer extended from the middle layer on one of the top surface and the bottom surface,

wherein the velvet plush article is made in synthetic materials such as polyester and the pile layer provides a highly smooth and soft touch and feel to a user.

Preferably, a color and/or a pattern is provided to the flat body of the velvet plush article. It is worth mentioning that the velvet plush article can also be a velvet plush blanket or simply a velvet plush sheet for further processing.

Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a velvet plush article according to a preferred embodiment of the present invention.

FIG. 2 is a cross section illustration of a velvet plush article according to the above preferred embodiment of the present invention.

FIG. 3 is an illustration of a method of manufacturing velvet plush article according to the above preferred embodiment of the present invention.

FIG. 4 is an illustration of a method of manufacturing velvet plush article according to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1 to 4 of the drawings, a method of manufacturing velvet plush article and a final velvet plush article are illustrated. The method of manufacturing a velvet plush article comprises the steps of:

(a) weaving a greige cloth;

(b) pre-processing the greige cloth from step (a);

(c) dyeing the greige cloth after step (b);

(d) printing the greige cloth after step (b) or (c); and

(e) finishing process the greige cloth to form a final velvet plush article.

It is worth mentioning that dyeing and printing are optional steps as desired in order to create a particular color and pattern onto the velvet plush article.

In particular, as shown in FIGS. 1 and 2 of the drawings, the velvet plush article 10 has a flat body 12 having a middle layer 121 defining a top surface 1211 and a bottom surface 1212, and at least one pile layer 122 comprising a plurality of pile hair 1221 extended from the middle layer 121 on one of the top surface 1211 and the bottom surface 1212. Preferably, the velvet plush article 10, as shown in FIG. 2 of the drawings, is a velvet plush throw having two pile layers 122 on the top surface 1211 and the bottom surface 1212 respectively and the pile hair 1221 is uni-directional in which a direction of the pile hair 1221 at a frontward direction is the same as a direction of the pile hair at a backward direction. The velvet plush article 10 is made in synthetic materials such as polyester and the two pile layers 122 on the top surface 1211 and the bottom surface 1212 provide a highly smooth and soft touch and feel to a user. In addition, a color 14 and/or a pattern 16 is preferably provided on one or both of the two pile layers 122 on the top surface 1211 and/or the bottom surface 1212 of the body 12 of the velvet plush article 10. It is worth mentioning that the velvet plush article 10 can also be a velvet plush blanket or simply a velvet plush sheet for further processing.

In particular, as shown in FIGS. 3 and 4 of the drawings, the method of manufacturing a velvet plush article comprises the steps of:

(a.1) weaving a greige cloth by interweaving face yarns and backing yarns, wherein the face yarns are selected from a group consisting of single-ply bright trilobal yarns with 75D/144F, 90D/144F, 100D/144F or 150D/288F and two-ply yarns with 120D/288F-300D/574F, wherein the backing yarns are selected from FDY 68D-100D or DTY 100D-150D;

(b.1) pre-processing the greige cloth obtained from step (a.1) by brushing, first setting, singeing and second setting the greige cloth sequentially;

(c.1) dyeing the greige cloth after step (b.1) to form a colored greige cloth; and

(e.1) finishing the colored greige cloth by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting the colored greige cloth.

Alternately, after the step (b.1) or (c.1), the method of manufacturing a velvet plush article further comprises the steps of:

(d.1) printing the greige cloth obtained from the step (b.1) or printing the colored greige cloth obtained from the step (c.1) to form a printed greige cloth; and

(e.1) finishing the colored greige cloth or the printed greige cloth by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting the colored or printed greige cloth sequentially.

Preferably, in step (a.1), a first and a second filaments are provided and a ratio of the first filament to the second filament is 4:1, wherein the first filament is a backing filament.

Preferably and in particular, in step (b.1), the brushing involves brushing along a frontward direction as well as brushing at a backward direction; the first setting involves heat-setting at 130-120° C. at a rolling speed of 25 m/min; the singeing involves a sequential rolling for six times at a frontward, backward, backward, frontward, backward and backward directions; the second setting involves heat-setting at 170-180° C. at a rolling speed of 25 m/min.

In particular, in step (c.1), dyeing the greige cloth includes bathing in dye fluid and rinsing by water. Preferably, an additional dyeing time is required for bathing and a pH of the water for rinsing is neutral or has a lowest acidity for providing a smooth and bright surface. The additional dyeing time for bathing is 20 minutes.

In particular, in step (d.1), printing includes the steps of brushing at a frontward direction, setting at 150° C. at a rolling speed of 25 m/min, and printing a preset pattern.

Preferably, in the step (e.1), softening includes washing to add acidity until the greige cloth is soft and then neutralizing the greige cloth until a pH of the greige cloth is neutral. It is worth mentioning if the pH is smaller than 7, then hair loss will occur. If the pH is greater than 7, the greige cloth will be hardened; drying includes drying under 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300 rpm and a lower drying channel operated at 1200 rpm; brushing includes brushing for two times; stentering includes stentering at a frontward direction and a backward direction; heat-setting includes heat-setting under 150° C. at a rolling speed of 25 m/min with soft air; singeing includes singeing at a frontward direction and a backward direction, and preferably includes singeing at a backward, backward, frontward, frontward, backward, frontward, backward and frontward directions sequentially; shearing includes shearing at a frontward, backward, backward, frontward, frontward, frontward, backward and backward directions sequentially such that the final direction of the hair at a frontward direction and at a backward direction are the same; and final heat-setting includes heat-setting at 190° C. at a rolling speed of 30 m/min.

One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. 

What is claimed is:
 1. A method of manufacturing a velvet plush article, comprising the step of: (a) weaving a greige cloth by synthetic yarn materials; (b) pre-processing the greige cloth; (c) dyeing the greige cloth to form a colored greige cloth; and (e) finishing the colored greige cloth to form a final velvet plush article, whereby the final velvet plush article has a flat body having a middle layer and at least one pile layer defining a plurality of pile hair, wherein the pile hair of the pile layer is uni-directional and is highly smooth and soft to provide a superior soft and smooth touch and feel effect.
 2. The method, as recited in claim 1, wherein the synthetic yarn materials are polyester and the velvet plush article is a velvet plush throw.
 3. The method, as recited in claim 2, wherein the flat body of the final velvet plush article has two pile layers on a top surface and a bottom surface of middle layer of the flat body respectively.
 4. The method, as recited in claim 1, after step (c), further comprising a step (d): printing the colored greiged cloth such that a pattern is provided.
 5. The method, as recited in claim 3, after step (c), further comprising a step (d): printing the colored greiged cloth such that a pattern is provided.
 6. A method of manufacturing a velvet plush article, comprising the step of: (a.1) weaving a greige cloth by interweaving face yarns and backing yarns, wherein the face yarns are single-ply bright trilobal yarns or two-ply yarns and the backing yarns are FDY or DTY yarns; (b.1) pre-processing the greige cloth obtained from step (a.1) by brushing, first setting, singeing and second setting process sequentially to obtain a pre-processed greige cloth; (c.1) dyeing the pre-processed greige cloth to form a colored greige cloth; and (e.1) finishing by softening, drying, brushing, stentering, heat-setting, singeing, shearing and final heat-setting process sequentially to form a final velvet plush article, whereby the final velvet plush article has a flat body having a middle layer and two pile layers defining a plurality of pile hair, wherein the pile hair of the pile layers are uni-directional and is highly smooth and soft to provide a superior soft and smooth touch and feel effect.
 7. The method, as recited in claim 6, after step (d.1), further comprising the step of: (d.1) printing the colored greige cloth such that a pattern is provided onto the colored greige cloth.
 8. The method, as recited in claim 6, wherein in the step (a.1), the single-ply bright trilobal yarns are selected from a group of yarns with 75D/144F, 90D/144F, 100D/144F and 150D/288F, the two-ply yarns are selected from a group of yarns with 120D/288F˜300D/574F, and the backing yarns are yarns selected from FDY 68D-100D or DTY 100D-150D.
 9. The method, as recited in claim 7, wherein in the step (a.1), the single-ply bright trilobal yarns are selected from a group of yarns with 75D/144F, 90D/144F, 100D/144F and 150D/288F, the two-ply yarns are selected from a group of yarns with 120D/288F-300D/574F, and the backing yarns are yarns selected from FDY 68D-100D or DTY 100D-150D.
 10. The method, as recited in claim 8, wherein in the step (a.1), the face yarn and the backing yarn has a ratio of 4:1 by weight.
 11. The method, as recited in claim 9, wherein in the step (a.1), the face yarn and the backing yarn has a ratio of 4:1 by weight.
 12. The method, as recited in claim 10, wherein in the step (b.1), the brushing process includes brushing along a frontward direction as well as brushing at a backward direction; the first setting process includes heat-setting under 130-120° C. at a rolling speed of 25 m/min; the singeing process includes a sequential rolling for six times at a frontward, backward, backward, frontward, backward and backward directions respectively; and the second setting process includes heat-setting under 170-180° C. at a rolling speed of 25 m/min.
 13. The method, as recited in claim 11, wherein in the step (b.1), the brushing process includes brushing along a frontward direction as well as brushing at a backward direction; the first setting process includes heat-setting under 130-120° C. at a rolling speed of 25 m/min; the singeing process includes a sequential rolling for six times at a frontward, backward, backward, frontward, backward and backward directions respectively; and the second setting process includes heat-setting under 170-180° C. at a rolling speed of 25 m/min.
 14. The method, as recited in claim 12, wherein in the step (c.1), further comprising the substeps of: (c.11) bathing in dye fluid and (c.12) rinsing by water, wherein a pH of the water for rinsing is neutral or has an acidity which is the lowest for providing a smooth and bright surfacing effect to the greige cloth.
 15. The method, as recited in claim 13, wherein in the step (c.1), further comprising the substeps of: (c.11) bathing in dye fluid and (c.12) rinsing by water, wherein a pH of the water for rinsing is neutral or has an acidity which is the lowest for providing a smooth and bright surfacing effect to the greige cloth.
 16. The method, as recited in claim 14, wherein in the step (e.1), the softening process includes washing to add acidity until the greige cloth is soft and then neutralizing the greige cloth until a pH of the greige cloth is neutral; the drying process includes drying under 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300rpm and a lower drying channel operated at 1200 rpm; the brushing process includes brushing for two times; the stentering process includes sequentially stentering at a frontward direction and a backward directions respectively; the heat-setting process includes heat-setting under 150° C. at a rolling speed of 25 m/min; the singeing process includes sequential singeing at a backward, backward, frontward, frontward, backward, frontward, backward and frontward directions respectively; the shearing process includes shearing at a frontward, backward, backward, frontward, frontward, frontward, backward and backward directions sequentially such that the final direction of the pile hair at a frontward direction and at a backward direction are the same; and the final heat-setting process includes heat-setting under 190° C. at a rolling speed of 30 m/min.
 17. The method, as recited in claim 16, wherein in the step (e.1), the softening process includes washing to add acidity until the greige cloth is soft and then neutralizing the greige cloth until a pH of the greige cloth is neutral; the drying process includes drying under 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300rpm and a lower drying channel operated at 1200 rpm; the brushing process includes brushing for two times; the stentering process includes sequentially stentering at a frontward direction and a backward directions respectively; the heat-setting process includes heat-setting under 150° C. at a rolling speed of 25 m/min; the singeing process includes sequential singeing at a backward, backward, frontward, frontward, backward, frontward, backward and frontward directions respectively; the shearing process includes shearing at a frontward, backward, backward, frontward, frontward, frontward, backward and backward directions sequentially such that the final direction of the pile hair at a frontward direction and at a backward direction are the same; and the final heat-setting process includes heat-setting under 190° C. at a rolling speed of 30 m/min. 